1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de produção agregadas? Para gerentes de fábrica e empreiteiros de engenharia, os principais desafios na britagem primária geralmente incluem:

Tempo de inatividade excessivo para manutenção: Frequent liner changes and unexpected component failures halt your entire processing line, custando milhares por hora em perda de produção.
Gradação inconsistente do produto: Fluctuations in feed size or hardness lead to offspec output, causing bottlenecks in secondary stages and reducing salable product yield.
Alto consumo de peças de desgaste: The constant abrasion and impact in the crushing chamber result in unsustainable costs for manganese steel jaws, pratos, e outros consumíveis.
Ineficiência Energética: Older or poorly designed crushers draw excessive power for their throughput, tornando a energia uma das três principais despesas operacionais.
Rigidity to Feed Variations: Can your primary crusher handle a mix of abrasive river gravel, hard granite, and recycled concrete without constant adjustment or choking?

A questão central é: how do you secure a primary crushing solution that delivers not just rock reduction, but predictable costperton performance and operational reliability?

2. VISÃO GERAL DO PRODUTO

Esta linha de produtos abrange serviços pesados Private Label Jaw Crushers projetado para aplicações de britagem primária. These machines are built to your specifications and branded under your company name, providing a tailored solution without the premium of a massmarket OEM.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Material de alimentação grande (até 80% do britador gape) é carregado no alimentador vibratório do urso pardo (opcional), que contorna multas para aumentar o rendimento primário.
2. Esmagamento por compressão: Material enters the fixed and movable jaw die cavity. The elliptical motion of the movable jaw applies intense compressive force against the fixed jaw, fracturing the rock.
3. Ajuste de configuração de descarga: O tamanho do produto triturado é controlado com precisão ajustando hidraulicamente ou mecanicamente a folga no ponto de descarga (CSS Closed Side Setting).
4. Descarga & Transporte: Sized material exits the bottom of the crushing chamber onto a main conveyor belt for transport to secondary screening or crushing stages.

Escopo de aplicação & Limitações:
Escopo: Ideal for stationary and portable plants processing hard rock (granito, basalto), material abrasivo (cascalho do rio, quartzito), concreto/asfalto reciclado, and lowabrasion mining ores. Suited for hightonnage primary stations.
Limitações: Não projetado para pegajoso, plasticclay materials which can cause chamber packing. Requires prescreening or effective grizzly feeding for optimal efficiency with finesladen material.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Cinemática Otimizada | Base Técnica: Maior profundidade de abertura de alimentação e ângulo de corte mais acentuado | Benefício Operacional: Allows for larger feed size acceptance and promotes aggressive drawing of material into the crushing zone on each cycle | Impacto do ROI: Higher throughput per cycle reduces total machine cycles for same output, lowering wear per ton.

Construção de estrutura para serviços pesados | Base Técnica: Fabricated from highgrade steel plate with reinforced ribbing | Benefício Operacional: Provides exceptional structural integrity to withstand decades of high cyclic loading with minimal frame stress or fatigue | Impacto do ROI: Elimina o risco de falha catastrófica da estrutura, garantindo a integridade dos ativos a longo prazo e protegendo o seu investimento de capital.

Ajuste de alternância hidráulica & Sistema de compensação | Base Técnica: Replaces traditional manual toggle plates with a hydraulic ram system | Benefício Operacional: Enables remote adjustment of CSS for product size changes and provides rapid unblocking of chamber obstructions in minutes | Impacto do ROI: Reduz o tempo de inatividade para ajustes em até 80% em comparação com sistemas de calços manuais; prevents extended stoppages from tramp metal or bridging.

Revestimentos de desgaste BoltOn & Mordentes Modulares | Base Técnica: Standardized liner attachment system with reversible/interchangeable jaw die segments | Benefício Operacional: Simplifies maintenance procedures; extends liner life through rotation/reversal options; reduces changeout time | Impacto do ROI: Lowers labor costs for liner maintenance by an average of 30% and maximizes utilization of wear material.

HighCapacity Spherical Roller Bearings | Base Técnica: Oversized bearings selected for dynamic load rating exceeding peak operational forces | Benefício Operacional: Runs cooler under load with higher tolerance for shock loads from uncrushables; designed for L10 life exceeding 50,000 horas | Impacto do ROI: Virtually eliminates premature bearing failure—a leading cause of major crusher repair—dramatically reducing total cost of ownership.

Ponto de lubrificação centralizado & Lube Monitoring | Base Técnica: Singlepoint lube distribution to all critical bearings with optional pressure/temperature sensors | Benefício Operacional: Ensures consistent lubrication during operation; provides diagnostic data to predict maintenance needs before failure occurs | Impacto do ROI: Proactive maintenance scheduling prevents unplanned stops; reduces lubricant waste through controlled application.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Média) | Private Label Jaw Crusher Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade / Tempo de atividade | 8590% (agendado & paradas não programadas) |> 94% meta de disponibilidade| >59% melhoria |
| Use a vida (Mandíbula morre rocha abrasiva) | 120,000 150,000 toneladas por conjunto| Field data shows consistent range of 180,000 220,000 toneladas por conjunto| +20% para +40% melhoria |
| Consumo de energia (kWh/tonelada) Varies by rock type.| Baseline set by older designs.| Cinemática otimizada & drive efficiency reduce specific energy draw.| Redução documentada de 812% |
| Tempo de ajuste CSS (Mecânico versus. Hidráulico)| Manual shim adjustment can take 48 horas.| Hydraulic toggle system enables adjustments in <1 hour.| Downtime reduction up to ~85% |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Taxa de transferência dependente do modelo de 200 MT/hr to over 1,200 MT/hora.
Abertura de alimentação: Gape sizes from 800mm x 600mm up to 1500mm x 1300mm.
Requisitos de energia: Motor de acionamento de 75 kW até 300 kW; standard voltage configurations available (400V/50Hz, 460V/60 Hz).
Especificações de materiais: Estrutura de aço soldada de alta resistência (S355J2+). Matrizes de mandíbula de aço manganês (18%/22% Mn). Eixo excêntrico de liga de aço forjado.
Dimensões Físicas / Peso: Varia significativamente por modelo; approximate footprint range from ~25m² to ~60m²; weights from ~25 tonnes to over ~80 tonnes.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Vedações contra poeira classificadas para condições padrão de pedreira; optional kits available for severe environments.

_(Throughput dependent on feed material characteristics and closed side setting.)_

6. CENÁRIOS DE APLICAÇÃO

Granite Quarry Primary Station Upgrade

Desafio: A large granite quarry faced declining profit margins due to weekly downtime for jaw die rotation/changeouts on their aging primary crusher and poor energy efficiency.
Solução: Implementation of a highcapacity private label jaw crusher featuring hydraulic toggle adjustment and modular wear liners as the new primary station cornerstone.
Resultados: Die changeout frequency reduced from every ~140k tons to every ~190k tons. Combined with faster CSS adjustments for different products, overall plant availability increased by an estimated annual production gain equivalent to two weeks' output at previous rates.

Concreto Reciclado & Asfalto (RCA) Processing Plant

Desafio: A new urban recycling plant needed a single primary crusher capable of handling highly variable feed—from soft asphalt slabs to reinforced concrete chunks—without constant blockages or rapid wear degradation.
Solução: Installation of a robust private label jaw crusher configured with an integrated hydraulic clearing system specifically designed as their private label RCA processing machine.
Resultados: The plant achieved consistent <4" minus product directly from primary crushing across all feed types. The clearing system resolved an average of two potential blockages per shift in under five minutes each, maintaining continuous feeding operations crucial for contract fulfillment.

7. CONSIDERAÇÕES COMERCIAIS

Our private label stone crusher program is structured around providing capital efficiency while maintaining performance integrity.

Pricing Tiers Based on Specification Level
Nível I: Estrutura central para serviço pesado & drive system with mechanical adjustment shims.
Nível II: Adds hydraulic toggle adjustment/clearing system as standard.
Nível III: Fully integrated package including automationready sensors/probes and premium wear liner metallurgy options.

Recursos opcionais
3D CAD model package provided upon purchase
12month extended warranty coverage
24month scheduled parts kit

Pacotes de serviços
Suporte de comissionamento: Onsite supervision during installation/startup included at Tier II+ levels
Planos de Manutenção Preventiva: Annual inspection programs tailored based on operating hours

Opções de financiamento
Flexible commercial terms are available through our partner network including equipment leasing structures that allow you preserve working capital while upgrading your production capability

Perguntas frequentes

Que nível de personalização é possível em seu programa de marca própria?

We provide significant engineering flexibility within proven design parameters You can specify features like motor brand preferences discharge conveyor mounting points paint schemes control panel integration points We will not compromise on core structural or mechanical integrity but will work closely with you on configuration details

How does wear part compatibility work? Are we locked into singlesource supply?

No Our private label jaw crushers are designed around industrystandard dimensions We provide full technical drawings that allow any qualified foundry or parts supplier who meets our material specifications produce compatible wear parts This protects you from future supply chain monopolies

What documentation is provided?

You receive complete documentation including foundation drawings general arrangement diagrams parts manuals lubrication schedules recommended spare parts lists This ensures your maintenance team has all necessary information independent operation

What is typical lead time from order placement delivery?

Lead times vary based model complexity current production schedule Standard configurations typically have lead time between weeks months upon finalization technical specifications We provide regular updates throughout manufacturing process

Você oferece garantias de desempenho?

Yes We provide guaranteed capacity ratings based agreedupon feed material characteristics laboratory test results Guarantees cover mechanical performance structural soundness within defined operating conditions These are detailed commercial agreement